Steps:
- 1. Line a baking sheet with foil; coat foil with cooking spray. Set aside. 2. Place popcorn in a large zip-top plastic bag; seal. Crush popcorn using a meat mallet or rolling pin; set aside. 3. Combine sugar, syrup, and 1/4 c water in a medium saucepan over medium heat. Cook 1 minute or until sugar dissolves; stirring constantly. Cook without stirring until a candy thermometer registers 270 (about 8 minutes). Stir in molasses and butter; cook until thermometer registers 290 (about 5 minutes). Stir in baking soda, vanilla, and salt. Stir popcorn into boiling syrup mixture. Working quickly, pour popcorn mixture into prepared pan; spread to 1/4-inch thickness using a wooden spoon coated with cooking spray. Cool completely; break into large pieces. Store brittle in an airtight container at room temperature for up to four days.
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